CN118164201B - A method and system for detecting material blockage at a blanking port based on optical flow - Google Patents
A method and system for detecting material blockage at a blanking port based on optical flowInfo
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- CN118164201B CN118164201B CN202410275141.8A CN202410275141A CN118164201B CN 118164201 B CN118164201 B CN 118164201B CN 202410275141 A CN202410275141 A CN 202410275141A CN 118164201 B CN118164201 B CN 118164201B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G43/00—Control devices, e.g. for safety, warning or fault-correcting
- B65G43/08—Control devices operated by article or material being fed, conveyed or discharged
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G65/00—Loading or unloading
- B65G65/30—Methods or devices for filling or emptying bunkers, hoppers, tanks, or like containers, of interest apart from their use in particular chemical or physical processes or their application in particular machines, e.g. not covered by a single other subclass
- B65G65/34—Emptying devices
- B65G65/40—Devices for emptying otherwise than from the top
- B65G65/42—Devices for emptying otherwise than from the top using belt or chain conveyors
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- G—PHYSICS
- G06—COMPUTING OR CALCULATING; COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/20—Analysis of motion
- G06T7/269—Analysis of motion using gradient-based methods
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- G—PHYSICS
- G06—COMPUTING OR CALCULATING; COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/60—Analysis of geometric attributes
- G06T7/62—Analysis of geometric attributes of area, perimeter, diameter or volume
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2201/00—Indexing codes relating to handling devices, e.g. conveyors, characterised by the type of product or load being conveyed or handled
- B65G2201/04—Bulk
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/02—Control or detection
- B65G2203/0208—Control or detection relating to the transported articles
- B65G2203/0241—Quantity of articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/04—Detection means
- B65G2203/041—Camera
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- G—PHYSICS
- G06—COMPUTING OR CALCULATING; COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T2207/00—Indexing scheme for image analysis or image enhancement
- G06T2207/10—Image acquisition modality
- G06T2207/10016—Video; Image sequence
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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- Physics & Mathematics (AREA)
- Computer Vision & Pattern Recognition (AREA)
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- Theoretical Computer Science (AREA)
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- Image Analysis (AREA)
Abstract
本发明涉及一种基于光流的落料口堵料检测方法及系统，该方法包括：S1、通过摄像设备不断采集落料口区域的视频图像，以实时监测落料口区域的物料运动；S2、对获得的视频图像中的连续图像帧进行比对，通过光流法分析并提取图像中的物料；S3、利用光流分析结果，分析料流面积；S4、利用光流分析结果，分析料流运动方向；S5、结合料流面积和料流运动方向的分析结果，进行料流状态判别：如果料流面积增大至超过料流面积阈值且料流运动方向弥散程度超过弥散度阈值，判定当前落料口即将发生堵料，否则判定当前落料口状态正常；S6、如果判定落料口即将发生堵料，即进行堵料告警。该方法及系统自动化程度高，可以提高落料口堵料检测的实时性和准确性。
The present invention relates to a method and system for detecting material blockage at a feed opening based on optical flow. The method comprises: S1, continuously capturing video images of the feed opening area through a camera device to monitor material movement in the feed opening area in real time; S2, comparing consecutive image frames in the obtained video images, analyzing and extracting materials in the images through optical flow analysis; S3, analyzing the material flow area using the optical flow analysis results; S4, analyzing the material flow movement direction using the optical flow analysis results; S5, combining the analysis results of the material flow area and the material flow movement direction to determine the material flow state: if the material flow area increases to exceed a material flow area threshold and the degree of dispersion in the material flow movement direction exceeds a dispersion threshold, it is determined that the current feed opening is about to be blocked; otherwise, it is determined that the current feed opening is in normal state; S6, if it is determined that the feed opening is about to be blocked, a blockage alarm is issued. The method and system have a high degree of automation and can improve the real-time and accuracy of feed opening blockage detection.
Description
Technical Field
The invention relates to the field of conveyor belt transportation, in particular to a blanking port blocking detection method and system based on optical flow.
Background
The blanking port plays a key role in conveying the conveyor belt, and whether the blanking port is unblocked directly influences the normal operation and the production efficiency of the production line. The blocking refers to the fact that materials cannot normally pass through the blanking port due to various reasons in the conveying process of the conveyor belt. The blockage may cause a series of serious problems such as production line stagnation, equipment damage and the like. The primary problem caused by the blockage is the stagnation of the production line. Once the blockage occurs, the conveyor belt will stop running, resulting in a temporary interruption of the production line and a drastic decrease in production efficiency. In addition, the prolonged downtime may cause equipment failure, which can have a more serious impact on the overall production process. The plugging may also cause additional wear to the equipment, increase maintenance costs, and even cause damage to the equipment. Therefore, it is important to monitor the blocking of the blanking port. The traditional monitoring mode is manual inspection. However, the manual inspection mode has the problems of human resource waste and low reaction speed, and is easy to miss inspection for some fine blocking situations. In order to realize automatic monitoring of blanking mouth putty condition, some blanking mouth putty detection techniques based on computer vision also appear in the prior art, but most of these detection techniques detect the effect poorly, can't discover the emergence of putty in real time, accurately.
Disclosure of Invention
The invention aims to provide a blanking port blocking detection method and system based on an optical flow, which have high automation degree and can improve the real-time performance and accuracy of blanking port blocking detection.
In order to achieve the purpose, the technical scheme adopted by the invention is that the blanking port blocking detection method based on optical flow comprises the following steps:
S1, continuously collecting video images of a blanking port area through camera equipment so as to monitor the material movement of the blanking port area in real time;
s2, comparing continuous image frames in the obtained video images, and analyzing and extracting materials in the images by an optical flow method;
s3, analyzing the area of the material flow by utilizing the optical flow analysis result;
S4, analyzing the movement direction of the material flow by utilizing an optical flow analysis result;
S5, combining analysis results of the material flow area and the material flow movement direction, and judging the material flow state, wherein if the material flow area is increased to exceed a material flow area threshold value and the dispersion degree of the material flow movement direction exceeds a dispersion degree threshold value, the current blanking port is judged to be blocked, otherwise, the current blanking port is judged to be normal;
S6, if the blanking port is judged to be blocked, blocking alarm is carried out.
Further, in step S2, the specific method for analyzing and extracting the material in the image by the optical flow method is as follows:
Global optical flow images L (x, y) are extracted through front and back frame images, pixel motion in the direction of a Cartesian coordinate system (x, y) is converted into the direction and amplitude of motion of a polar coordinate system (sigma, r), and an optical flow image L (sigma, r) expressed by the polar coordinate system is obtained:
The material is the part with larger motion amplitude and the image ratio is small, so the pixels with smaller motion amplitude in the image are regarded as background, the histogram of the amplitude component of the light flow graph L (sigma, r) is calculated, the amplitude is divided into N intervals, the interval is defined as A 1,A2,…,AN, wherein M is the amplitude, the accumulated number in each interval is counted, the optical flow pixels in the first interval are removed, because the motion amplitude is small and the number is large, namely the motion amplitude is smaller than the background of the first interval, the rest is foreground material, a threshold value is set
The optical flow pixels in the remaining intervals are moving materials because they have large motion amplitudes and a small number.
Further, the number of intervals n=20.
Further, in step S3, for all materials extracted from the image, the materials are combined to obtain a flow area, then an envelope curve of the flow area is made, and the area of the flow envelope area is calculated, namely, the flow area a.
Further, if the flow area A is not larger than the set flow area threshold T a, the state of the blanking port is judged to be normal, and if the flow area A is larger than the flow area threshold T a, namely A > T a, the risk of blocking is considered, but the blocking is not directly judged, and the blocking condition is analyzed together with the flow movement direction.
Further, in step S4, the dispersion degree of the stream movement direction is described by using the stream movement standard deviation epsilon, which specifically is:
Wherein sigma i is the pixel direction sample, Q is the sample number, Is the direction average value.
Further, in step S5, based on the set flow area threshold T a and the dispersion threshold T σ, it is determined whether the flow area a > T a and the flow movement standard deviation epsilon > T σ are simultaneously satisfied, if yes, it is determined that the current blanking port is about to be blocked, otherwise, it is determined that the current blanking port is in a normal state.
The invention also provides a blanking port blocking detection system based on the optical flow, which is used for realizing the method and comprises the following steps:
The camera equipment is arranged above the blanking port of the conveyor belt, and is used for collecting video images of the blanking port area and sending the collected video images to the upper computer;
the upper computer is connected with the camera equipment and used for receiving the collected video image, analyzing and extracting materials in the image through an optical flow method, analyzing the flow area and the flow moving direction, and judging the flow state by combining the analysis results of the flow area and the flow moving direction.
Further, the blanking device comprises an alarm device, and the upper computer is connected with the alarm device so as to perform blanking alarm through the alarm device when the blanking port is judged to be blocked.
Compared with the prior art, the blanking port blocking detection method and system based on the optical flow have the advantages that the imaging equipment is arranged on the conveyor belt, video images of blanking port areas are shot in real time, the optical flow state between front and rear frame images is analyzed by the optical flow analysis technology, the material flow area and the material flow moving direction are obtained through analysis, and then the blanking port blocking state is judged by combining the material flow area and the material flow moving direction. Therefore, the invention has strong practicability and wide application prospect.
Drawings
FIG. 1 is a flow chart of a method implementation of an embodiment of the present invention;
FIG. 2 is a histogram of optical flow magnitude in an embodiment of the invention;
FIG. 3 is a diagram of a process for extracting materials in an embodiment of the present invention;
FIG. 4 is a schematic view of a flow envelope region when no plugging has occurred in an embodiment of the present invention;
FIG. 5 is a schematic view of the envelope region of the flow when a blockage occurs in an embodiment of the invention;
FIG. 6 is a schematic view of the direction of motion of a stream in an embodiment of the invention;
Fig. 7 is a system implementation schematic diagram of an embodiment of the present invention.
Detailed Description
The invention will be further described with reference to the accompanying drawings and examples.
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the application. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present application. As used herein, the singular is also intended to include the plural unless the context clearly indicates otherwise, and furthermore, it is to be understood that the terms "comprises" and/or "comprising" when used in this specification are taken to specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof.
As shown in fig. 1, the embodiment provides a blanking port blocking detection method based on optical flow, which specifically includes the following implementation steps.
S1, collecting real-time images, namely continuously collecting video images of the blanking port area through the camera equipment so as to monitor the material movement of the blanking port area in real time.
S2, analyzing the optical flow of the frames before and after the image, namely comparing the continuous image frames in the obtained video image, and analyzing and extracting materials in the image by an optical flow method. Optical flow is a vector field describing the motion of pixels in an image, and can reflect the motion trail of an object in the image.
S3, analyzing the flow area by utilizing the optical flow analysis result. When the material movement is normal, the material flow area is relatively small, and when the material is about to be blocked, the material flow area is obviously increased.
S4, analyzing the movement direction of the material flow by utilizing the optical flow analysis result. The movement direction of the material in the image is analyzed, and when the material flow directions are consistent, the material flow is smooth, otherwise, if the material flow directions are dispersed, the situation that the material blockage is about to occur is possibly indicated.
S5, combining the analysis results of the flow area and the flow movement direction, and judging the flow state. If the flow area is increased to exceed the flow area threshold and the dispersion degree of the flow movement direction exceeds the dispersion threshold, judging that the current blanking port is about to be blocked, otherwise, judging that the current blanking port is normal.
S6, if the blanking port is judged to be blocked, blocking alarming or information feedback is carried out so as to carry out timely maintenance and treatment.
By the detection method, the state of the blanking port can be accurately analyzed according to the real-time video, the impending blocking situation can be early warned in time, and a reliable monitoring means is provided for the production process.
In order to achieve the above-mentioned method, as shown in fig. 7, the present embodiment further provides a blanking port blocking detection system based on optical flow, which includes an image capturing device and an upper computer.
The camera equipment is arranged above the blanking port of the conveyor belt and used for collecting video images of the blanking port area and sending the collected video images to the upper computer.
The upper computer is connected with the camera equipment and is used for receiving the collected video image, analyzing and extracting materials in the image through an optical flow method, analyzing the flow area and the flow moving direction, and judging the flow state by combining the analysis results of the flow area and the flow moving direction.
Preferably, the system further comprises an alarm device, wherein the upper computer is connected with the alarm device, so that when the blanking port is judged to be blocked, the alarm device can be used for blocking the material to give an alarm.
The related art to which the present method relates is described in further detail below.
(1) Optical flow extraction and material segmentation of frame materials before and after images
The stream is the object in the video that is located at the blanking port and is moving. The invention uses the light flow method to extract the materials in the image. Optical flow is the movement of the same object in an image between the previous and subsequent frames.
Global optical flow images L (x, y) are extracted through front and back frame images, pixel motion in the direction of a Cartesian coordinate system (x, y) is converted into the direction and amplitude of motion of a polar coordinate system (sigma, r), and an optical flow image L (sigma, r) expressed by the polar coordinate system is obtained:
Since the material is the part of the image with larger motion amplitude and occupies a small image ratio, the pixels of the image with smaller motion amplitude are considered as the background. Calculating a histogram of amplitude components of a light flow graph L (sigma, r), dividing the amplitude into N bins, the bins being defined as A 1,A2,…,AN, wherein M is the amplitude, and the accumulated number in each interval is counted. The histogram of optical flow amplitude is shown in fig. 2. In the present embodiment, the number of intervals n=20 is taken. Removing optical flow pixels in the first interval because of small and numerous motion amplitudes, namely taking the background with the motion amplitude smaller than that of the first interval and the rest foreground materials, setting a threshold value
The optical flow pixels in the remaining intervals are moving materials because they have large motion amplitudes and a small number.
The implementation process of the material extraction is shown in fig. 3. In fig. 3, from left to right, an original image, an optical flow visualization image and a material mask image are respectively shown.
(2) Flow surface area analysis
And combining all materials extracted from the image to obtain a material flow area, then, taking an envelope curve of the material flow area, and calculating the area of the material flow envelope area, namely the material flow area.
If the material flow area A is not larger than the set material flow area threshold T a, the state of the blanking port is judged to be normal, and if the material flow area A is larger than the material flow area threshold T a, namely A > T a, the risk of material blockage is considered, but the material blockage cannot be directly judged, and the material blockage condition needs to be analyzed together with the material flow moving direction. The flow envelope area when no plugging occurred is shown in fig. 4. In fig. 4, the left side is a diagram of the stream envelope region when no blockage occurs, and the right side is a corresponding monitoring video image. The flow envelope area when plugging occurs is shown in fig. 5. In fig. 5, the left side is a diagram of a flow envelope area when a blockage occurs, the flow envelope area increases and exceeds a set threshold, and the right side is a corresponding monitoring video image.
(3) Stream direction consistency analysis
When the blanking port is not blocked, the material flow is smooth, and when the material is blocked, the material flow moves towards all directions. Therefore, the invention adopts the consistency of the material flow direction as the condition of blanking mouth blocking analysis. As shown in the radar chart of fig. 6, the left side is the optical flow intensity and pattern without blockage, and the right side is the optical flow intensity and pattern with blockage. In contrast, the optical flow direction without the plugging material is more concentrated, the strength is larger in a certain direction, and the optical flow direction of the plugging material is dispersed.
In this embodiment, the dispersion degree of the stream movement direction is described by using the stream movement standard deviation epsilon, which specifically is:
Wherein sigma i is the pixel direction sample, Q is the sample number, Is the direction average value.
(4) Material flow state discrimination
Based on the set material flow area threshold T a and the dispersion threshold T σ, judging whether the material flow area A is more than T a and the material flow standard deviation epsilon is more than T σ at the same time, if yes, judging that the current blanking port is about to be blocked, otherwise, judging that the current blanking port is normal.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the invention in any way, and any person skilled in the art may make modifications or alterations to the disclosed technical content to the equivalent embodiments. However, any simple modification, equivalent variation and variation of the above embodiments according to the technical substance of the present invention still fall within the protection scope of the technical solution of the present invention.
Claims (8)
1. The blanking port blocking detection method based on the optical flow is characterized by comprising the following steps of:
S1, continuously collecting video images of a blanking port area through camera equipment so as to monitor the material movement of the blanking port area in real time;
s2, comparing continuous image frames in the obtained video images, and analyzing and extracting materials in the images by an optical flow method;
s3, analyzing the area of the material flow by utilizing the optical flow analysis result;
S4, analyzing the movement direction of the material flow by utilizing an optical flow analysis result;
S5, combining analysis results of the material flow area and the material flow movement direction, and judging the material flow state, wherein if the material flow area is increased to exceed a material flow area threshold value and the dispersion degree of the material flow movement direction exceeds a dispersion degree threshold value, the current blanking port is judged to be blocked, otherwise, the current blanking port is judged to be normal;
s6, if the blanking port is judged to be blocked, a blocking alarm is carried out;
in step S2, the specific method for analyzing and extracting the materials in the image by the optical flow method is as follows:
Global optical flow images L (x, y) are extracted through front and back frame images, pixel motion in the direction of a Cartesian coordinate system (x, y) is converted into the direction and amplitude of motion of a polar coordinate system (sigma, r), and an optical flow image L (sigma, r) expressed by the polar coordinate system is obtained:
The material is the part with larger motion amplitude and the image ratio is small, so the pixels with smaller motion amplitude in the image are regarded as background, the histogram of the amplitude component of the light flow graph L (sigma, r) is calculated, the amplitude is divided into N intervals, the interval is defined as A 1,A2,…,AN, wherein M is the amplitude, the accumulated number of each interval is counted, the optical flow pixels in the first interval are removed, the pixels have small and numerous motion amplitudes, namely the motion amplitude is smaller than that of the first interval, the rest are foreground materials, a threshold value is set
The optical flow pixels in the remaining intervals are moving materials because they have large motion amplitudes and a small number.
2. The method for detecting blocking of a blanking port based on an optical flow according to claim 1, wherein the number of intervals n=20.
3. The method for detecting blocking of a blanking port based on an optical flow according to claim 1, wherein in step S3, for all materials extracted from an image, a material flow area is obtained by combining all materials, then an envelope curve of the material flow area is obtained, and an area of the material flow envelope area is calculated, namely, a material flow area a.
4. The method for detecting blocking of a blanking port based on an optical flow according to claim 3, wherein if the flow area A is not larger than the set flow area threshold T a, the blanking port state is judged to be normal, and if the flow area A is larger than the flow area threshold T a, namely A > T a, the blocking risk is considered, but the blocking is not directly judged, and the blocking is analyzed together with the flow movement direction.
5. The method for detecting blocking of a blanking port based on optical flow according to claim 1, wherein in step S4, a standard deviation epsilon of flow motion is used to describe the dispersion degree of the flow motion direction, specifically:
Wherein sigma i is the pixel direction sample, Q is the sample number, Is the direction average value.
6. The method for detecting blocking of a blanking port based on an optical flow according to claim 1, wherein in step S5, based on a set flow area threshold T a and a dispersion threshold T σ, it is determined whether the flow area a > T a and the flow standard deviation epsilon > T σ are simultaneously satisfied, if yes, it is determined that blocking is about to occur in the current blanking port, otherwise, it is determined that the current blanking port state is normal.
7. A blanking port plugging detection system based on optical flow for implementing the method of any one of claims 1-6, comprising:
The camera equipment is arranged above the blanking port of the conveyor belt, and is used for collecting video images of the blanking port area and sending the collected video images to the upper computer;
the upper computer is connected with the camera equipment and used for receiving the collected video image, analyzing and extracting materials in the image through an optical flow method, analyzing the flow area and the flow moving direction, and judging the flow state by combining the analysis results of the flow area and the flow moving direction.
8. The system for detecting plugging of a blanking port based on an optical flow of claim 7, further comprising an alarm device, wherein the host computer is connected to the alarm device to alarm by the alarm device when it is determined that plugging of the blanking port is about to occur.
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| CN110910355A (en) * | 2019-11-07 | 2020-03-24 | 浙江大华技术股份有限公司 | Package blocking detection method and device and computer storage medium |
| CN116894857A (en) * | 2023-07-19 | 2023-10-17 | 河南京能滑州热电有限责任公司 | A material blockage detection method and terminal equipment |
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| KR20160093253A (en) * | 2015-01-29 | 2016-08-08 | 쿠도커뮤니케이션 주식회사 | Video based abnormal flow detection method and system |
| CN116062491A (en) * | 2023-03-11 | 2023-05-05 | 福建蔚视科技有限公司 | A laser line-based material blocking detection device and detection method for a belt transfer station |
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| CN110910355A (en) * | 2019-11-07 | 2020-03-24 | 浙江大华技术股份有限公司 | Package blocking detection method and device and computer storage medium |
| CN116894857A (en) * | 2023-07-19 | 2023-10-17 | 河南京能滑州热电有限责任公司 | A material blockage detection method and terminal equipment |
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